Method and machine for building tunnels



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United States Patent 3,442,088 METHOD AND MACHINE FOR BUILDING TUNNELS Bernard Borisof, 3530 N. Lake Shore Drive, Chicago, Ill. 60657 Filed Feb. 28, 1966, Ser. No. 537,603 Int. Cl. E21d 9/00; E01g 3/06; E02f 1/00 US. C]. 61-44 Claims ABSTRACT OF THE DISCLOSURE The disclosed method of building a tunnel contemplates providing a shelter or enclosure, placing the shelter over the right of way of the tunnel, excavating an open trench under the shelter, constructing a portion of the tunnel structure under the rear portion of the shelter, moving the shelter to a series of new locations along the right of way, excavating additional portions of the trench under the front portion of the shelter at the successive locatlons, and constructing additional portions of the tunnel structure under the rear portion of the shelter at the successive locations, whereby the tunnel building operations are substantially enclosed by the shelter. The disclosed machine comprises a portable shelter or enclosure having a rigid framework, wheels mounted on the shelter and supporting the shelter for movement along the tunnel right of way, a pair of spaced rails or tracks mounted on the inside of the shelter, a plurality of carriages having rollers or wheels supported on the rails so that the carriages are movable within the shelter, an excavator mounted on one of the carriages, and various material handling devices mounted on the other carriages. Such material handling devices include a crane, a cart for handling wet concrete to be placed in the trench, and turn tables for supporting trucks or the like so that they can be maneuvered quickly into position for loading and unloading, while obviating any need to back the trucks.

This invention relates to a method and machine for building tunnels, particularly tunnels for carrying vehicular trafiic.

One object of the present invention is to provide a new and improved method, and also a new and improved machine or apparatus, both of which are applicable generally to the construction of tunnels, but which are especially well adapted for building tunnels under city streets, for use as expressways by automobiles, trucks and other motor vehicles. Such expressway tunnels may be built under existing city streets, without the necessity for acquiring any additional right of way. The width of most city streets will provide at least two or three lanes of traffic in the expressway tunnel. Additional lanes may be provided by constructing twin tunnels under parallel city streets, for carrying traffic in opposite directions.

Inasmuch as such expressway tunnels may be constructed under existing streets, a complete expressway may be built without demolishing any buildings to make room for the necessary tunnels. Exit and entrance ramps to serve the tunnels will normally require the acquisition of a small amount of additional right of way, from which the existing buildings will have to be removed, but these small areas can be converted into parks or other .public facilities, after the expressway has been completed, so that there will be no substantial destruction or serious dislocation of existing neighborhoods.

The twin tunnels of such a tunnel expressway are preferably built under secondary city streets which run parallel and adjacent to a major street. In this way, the exit and entrance ramps for the expressway tunnels may be con- 3,442,088 Patented May 6, 1969 structed so as to receive and discharge traffic on the major street. When the expressway tunnels are completed, the movement of the surface traflic on the secondary streets will be approximately the same as it was before.

A further object of the present invention is to provide a new and improved method and machine whereby virtually the entire tunnel building operation may be conducted under cover, without being affected by the weather, and without creating any serious dust or noise problems, or any other serious disturbance to the neighborhood through which the tunnel is being built.

A further object is to provide such a new and improved method and machine whereby the tunnel building operation is enclosed within a portable shelter or enclosure which is moved forwardly along the right of way of the tunnel as the tunnel building operation progresses, the shelter preferably being mounted on Wheels to facilitate the movement of the shelter.

Another object is to provide such a new and improved method and apparatus whereby the building of the tunnel is highly mechanized by providing various mechanical devices and machines within the shelter, such devices including, for example, an excavating machine, a crane, a device for pouring concrete, and other material handling devices.

Another object is to provide a new and improved method and machine whereby tunnels may be built efficiently, rapidly, and at low cost.

Further objects and advantages of the present invention will appear from the following description, taken with the accompanying drawings, in which:

FIG. 1 is a diagrammatic perspective view showing a tunnel building machine to be described as an illustrative embodiment of the present invention, various portions of the machine being broken away for clarity of illustration.

FIG. 2 is a diagrammatic sectional view taken through an illustrative expressway tunnel intended particularly for carrying automobile trafiic.

FIG. 3 is a view similar to FIG. 2 but showing a modified expressway tunnel intended particularly for carrying truck trafiic.

The method of the present invention, as illustrated by way of example in the drawings, involves the provision of a portable shelter 10 which is movable along the right of way of the tunnel, so that the tunnel building operatrons may be conducted under cover, without interference from the weather. The shelter also confines the dust and noise which may be produced by the tunnel building operations, so as to avoid any serious effect upon the neighborhood through which the tunnel is being built.

Ifor the stake of economy, the tunnel is built 'by excavating an open trench 12. The tunnel structure 14 is then built in the open trench 12. The tunnel structure 14 preferably comprises a concrete slab 16 which is laid on the bottom of the trench 12, to provide pavement for the bottom of the tunnel. The tunnel structure 14 also comprises a pair of walls 18 and a roof 20, which are preferably poured as a monolithic concrete structure. The upper side of the roof 20 is substantially flush with the surface of the ground so that it forms the pavement for the surface street, running above the tunnel.

The excavation of the trench 12 is preferably carried out in the forward end portion of the shelter or enclosure 10, whlle the tunnel structure 14 is simultaneously being constructed in the rear portion of the shelter. In this way, all of the tunnel building operations may be carried on simultaneously under cover. When the desired section of the tunnel structure 14 has been completed, the entire shelter 10 is moved forwardly along the tunnel right of way, by an amount corresponding to the length of the completed section of the tunnel structure. Another section of the tunnel structure is then constructed in the portion of the trench '12 which was excavated at the previous 1oca- 3 tion of the shelter Simultaneously, an additional section of the trench 12 is excavated in the front portion of the shelter.

Of course, when the tunnel is just being started and the shelter is at its first position, the excavation of the trench 12 is carried out in both the rear and the front portions of the shelter. A section of the tunnel structure is then built under the rear portion of the shelter. At the subsequent positions of the shelter, the excavating and building operations are carried out simultaneously under the front and rear portions of the shelter. When the tunnel is being completed and the shelter is at its final position, the tunnel building operation is completed under both the front and rear portions of the shelter.

Preferably, the shelter 10 is in the form of an elongated portable building having a pair of side walls 22, a roof 24, a front wall 26 and a rear wall 28. The bottom of the shelter 10 is open throughout all or most of the length of the shelter so that the excavating and building operations may be carried out without interference from the shelter. It is preferred that the sides and top of the shelter be entirely closed so that the weather will be excluded from the shelter, while noise and dust are confined within the shelter. Preferably, the walls 22, 26 and 28, as well as the roof 24, are insulated for heat and sound. The inside of the shelter is preferably heated in cold weather and cooled in excessively warm weather to provide good working conditions at all times. Adequate lighting is provided within the shelter 10 so that the tunnel building operations can be proceed at night as well as in the daylight hours.

Wheels or rollers 30 are preferably mounted on the shelter 10 so as to support the shelter on the surface of the ground or street 32. The provision of the wheels 30 greatly facilitates the forward movement of the shelter along the right of way of the tunnel. The wheels 30 may be provided with propulsion motors for moving the shelter, but it is normally easier to use one or more suitable tractors or other vehicles to pull or push the shelter along the ground when it needs to be advanced. Hydraulic jacks or the like may also be employed to move the shelter.

An excavating device or 'machine 34 is preferably provided within the shelter 10 to dig the trench 12. Other material handling devices are also preferably provided within the shelter. In many cases, it will be desirable to employ steel piling 36 to shore up the walls of the trench 12. A crane 38 is preferably provided within the shelter 10 to drive the piling 36. The same crane, or one or more additional cranes, may be employed in connection with the construction of the tunnel structure 14, to hoist reinforcing steel, precast concrete members, and other materials.

Preferably, a concrete pouring machine 40 is provided within the shelter 10 to convey and lay the concrete for the slab 16, the walls 18 and the roof 20.

The earth and debris removed by the excavating machine 34 are removed by trucks which preferably are driven into the shelter 10 through openings or entrances 42 in the front wall 26. Overhead doors 44 are preferably provided to close the openings 42. To expedite the movement of the trucks, a turn-table 46 is preferably provided within the shelter 10 and adjacent the excavating machine 34. A ra'mp 47 may be provided between the turn-table 46 and the ground. FIG. 1 illustrates a dump truck 48 on the turn table 46. It will be understood that each truck is driven onto the turn-table. The turn-table may then be rotated to bring the truck into the best position for loading. When the truck has been loaded, the turn-table is rotated to head the truck toward the openings 42, so that the truck may be driven in a forward direction out of the shelter. The turn-table 46 obviates any need for backing the trucks into or out of the shelter.

Similarly, a turn-table 50 is preferably provided for tutlning trucks adjacent the concrete handling machine 40. A concrete mixer truck 52 is shown on the turn-table 50.

Such trucks, for handling concrete and other materials to be used in the construction of the tunnel, are driven into the shelter 10 through openings 54 in the rear end wall 28. Here again, overhead doors 56 are preferably employed to close the openings 54. A ramp 57 may be provided to carry the trucks between the completed tunnel structure and the turn-table 50. The turn-table 50 makes it,possible to turn the truck into the best position for unloading the wet concrete or other material. Moreover, the turn-table obviates any need for backing the trucks into or out of the shelter. Thus, the movement and manipulation of the trucks is greatly facilitated.

It will be understood that materials for use in building the tunnel may also be brought into the shelter 10 through the completed portion of the tunnel structure 14. In FIG. 1, a truck 58 is shown within the tunnel to illustrate this point.

It is preferred to provide a pair of spaced members or rails 60 within the shelter 10 to support the various machines and material handling devices. As shown, the rails 60 are positioned adjacent the opposite side walls 22 of the shelter. The trench 12 is dug in the space between the rails 60. Thus, the excavating machine 34 is preferably mounted on a carriage 62 having wheels or rollers 64 supported by the rails 60. It will be seen that the carriage 62 extends between or spans the rails or side members 60. The excavating machine 34 is adapted to travel along the rails and to excavate earth from the space between the rails.

Similar carriages 66, 68, 70 and 72 are provided to support the crane 38, the concrete pouring machine 40, and the turn-tables 46 and 50, respectively. In each case, the carriage is provided with a set of the wheels or rollers 64, which are supported on the rails 60.

In the illustrated construction, the supporting members or rails 60 are rigidly secured to the side walls 22 of the shelter and thus are incorporated into the structure of the shelter, so that the rails and all of the various machines and mechanical devices mounted thereon will be advanced as a unit when the shelter is moved forward along the right of way of the tunnel. The structure of the shelter 10 maintains the desired spacing between the rails 60. The supporting wheels 30 for the shelter 10 are preferably mounted on the supporting members 60.

It would be possible to provide the excavating machine, the crane, and the other material handling devices with their own ground wheels, so that these machines and devices could be moved directly along the surface of the ground within the shelter 10. However, it is preferred to provide the supporting rails to facilitate the movement of the various machines and to insure that the stability of the machines Will be maintained despite possible gaps or irregularities in the surface of the ground.

It would be possible to provide the side members 60, together with suitable interconnecting members, to form a rectangular frame for supporting excavating and material handling devices, while omitting the shelter. However, it is preferred to incorporate the side members 60 into the structure of the shelter 10 so that virtually the entire tunnel building operation can be carried out under cover. Moreover, the shelter, the supporting framework, and the travelling machines can then be advanced along the right of way as a unit.

FIGS. 2 and 3 illustrate examples of tunnels which may be constructed by the method and machine of the present invention. Thus, FIG. 2 illustrates a tunnel 74 intended particularly for carrying automobile trafiic. The tunnel 74 has two express lanes 76, plus a local or turnoff lane 78 which is used for carrying trafiic into and out of the tunnel through ramps 80 leading to the surface of the ground. The ramps 80 are preferably connected with a main street which runs parallel to the tunnel. Underground spaces or chambers 82 may be provided in connection with the ramps 80, for use as parking lots and service areas. Gasoline filling stations may be provided in some of the service areas.

The tunnel is also preferably provided with a sewer 84 extending alongside the traffic lanes to provide drainage for the tunnel. One or more ventilation ducts 86 are preferably provided above but separate from the sewer 84, together with one or more additional passages or ducts 88 for utility facilities, such as water pipes, gas pipes, electrical conduits and telephone cables. This arrangement has the advantage that all such utility facilities are readily accessible for maintenance or enlargement. Air filters and other purification equipment are preferably provided in connection with the ventilation ducts 86 to remove fumes and odors from the outgoing air before it is discharged above the surface.

A catwalk 90 preferably extends along one side of the tunnel for use by policemen and other supervisory personnel. The catwalk may be connected with various emergency exits leading from the tunnel.

As already indicated, the roof 20 of the tunnel serves as the pavement for the surface street. Surface trafiic may proceed along the street in the normal manner. The roof 20 may be formed with integral curbs 92 for the surface street.

It will be noted that the tunnel is fully concealed and completely invisible so that it does not detract from the appearance of the neighborhood. The tunnel confines the noise of the traffic, and virtually eliminates the fumes, so that these factors do not detract from the neighborhood. The tunnel provides greatly improved access to the neighborhood so that property values will be enhanced.

The surface areas over the ramps 80 and the underground parking and service areas 82 may be covered with earth and planted with grass and suitable shrubs and trees. In this way, parks and other attractive public areas may be provided adjacent the expressway tunnel.

Of course, adequate lighting is provided in the tunnel so that traffic may move safely and swiftly at all times. The traffic in the tunnel is not affected by adverse weather conditions.

FIG. 3 illustrates a slightly modified tunnel 94 which is intended particularly for carrying trucks and buses. The illustrated tunnel 94 provides one express lane 96 and one local lane 98. In addition to connecting with entrance and exit ramps, as in the case of the tunnel of FIG. 2, the tunnel 94 may connect with underground loading docks 100 and other similar facilities. Thus, trucks may move through, into and out of an area without causing surface congestion, noise or fumes.

It may be helpful to summarize the method of the present invention and the operation of the illustrated tunnel building machine. It will be assumed that a tunnel is to be built under an existing street. The side members 60, the associated framework, and the shelter are erected over the street. Preferably the shelter and the side members are made in sections which can be readily assembled and disassembled, so that they can be moved from one location to another with ease. If it becomes necessary to move the machine around an obstruction, the sections may be disassembled, moved to the new site and reassembled.

As the shelter 10 is assembled, the various excavating and material handling devices are put into place on the side members 60.

When the erection of the tunnel building machine has been completed, the excavating machine 34 is employed to dig the portion of the trench 12 under the shelter 10. The width of the trench 12 is somewhat less than the spacing between the side members or rails 60. The carriage 62 for the excavating machine 34 travels along the rails 60 so that the excavating machine may be advanced along virtually the full length of the shelter.

The excavation is completely concealed within the shelter 10. There is no possibility that members of the public will fall into the excavation and there is no need to erect barriers.

The carriage 70 for the turn-table 46 is moved along the rails 60 to a convenient location adjacent the excavating machine 34. The earth-hauling trucks for removing the excavated earth are then driven up the ramp 47 and onto the turn-table 46. The turn-table 46 is employed to turn each truck into the most convenient position for loading. After the truck has been loaded, the turn-table 46 is rotated so that the truck may be driven in a forward direction out of the shelter.

During the initial stages of the excavating operation, the turn-table 50 may also be employed to support earthhauling trucks. Such trucks may enter the shelter 10 through the openings 54 in the rear end wall 28.

As portions of the excavation are completed, the crane 38 may be employed to drive sheet piling so as to prevent the sides of the excavation from caving in. The crane 38 may also be employed to hoist reinforcing steel, precast concrete members, and other materials.

While the excavation is proceeding in the front end portion of the shelter 10, the tunnel structure 14 is built in the rear end portion. Normally, the concrete for the lower slab or floor 16 is laid first, with the assistance of the concrete pouring machine 40. The carriage 68 for the machine 40 is moved along the rails 60 to the point where the wet concrete is to be poured.

The carriage 72 for the turn-table 50 is then moved along the rails 60 to a point adjacent the concrete pouring machine 40. The concrete may be brought to the site in ready-mix trucks 52. A sectional platform 1.10 may be mounted on the rails 60 between the turn-table 50 and the ramp 57. Thus, each ready-mix truck may be driven up the ramp 57, along the platform and onto the turn-table 50. The turn-table 50 is rotated to bring the ready-mix truck into the most convenient position for unloading. After the concrete has been discharged from the truck, the turn-table 50 is rotated by an additional amount, if necessary, so that the truck may be driven out of the shelter in a forward direction. The provision of the turn-tables 46 and 50 eliminates any need for backing the trucks into or out of the shelter.

Suitable forms are erected for the casting of the walls 18 and the roof 20. The concrete is then poured into the forms with the use of the pouring machine 40 and the turntable 50.

The provision of the travelling turn-table 50, the travelling concrete handling machine 40, and the sectional platform 110 makes it possible to keep the heavy ready-mix trucks off the completed tunnel structure until the concrete has had time to cure and develop an adequate strength to sustain the weight of the trucks. When the concrete has cured sufficiently, trucks may be driven directly over the slab 16 and the tunnel structure 14 to bring in materials.

When the portion of the trench 12 has been fully excavated under the shelter 10, and when the tunnel structure has been built .part way along the length of the shelter, the entire tunnel building machine is preferably moved forwardly along the tunnel right of way by an amount corresponding to the length of the completed tunnel structure under the shelter. In this way, the excavation of the trench may be continued without delay. Moreover, the construction of the tunnel structure may be continued in the portion of the trench which was dug at the previous location of the tunnel building machine.

The shelter 10 protects the entire tunnel building operation from the weather. Thus, the tunnel building operation may be continued without delay at all seasons of the year. Furthermore, work on the tunnel may proceed at night as well as in the daytime.

The shelter 10 is preferably insulated for sound, as Well as heat. The sound insulation may advantageously comprise a thin sheet of lead. By confining noises, as well as dust, the shelter virtually eliminates any serious disturbance to the neighborhood in which the tunnel is being built. As the tunnel is completed, the surface street may be restored to its original condition, so that local traffic may proceed along the surface, as before. The tunnel pro- 7 vides an underground expressway for carrying trafiic very swiftly and efficiently into, through and out of the neighborhood.

Various other modifications, alternative constructions and equivalents may be employed without departing from the true spirit and scope of the invention, as exemplified in the foregoing description and defined in the following claims.

I claim:

1. A method of building a tunnel, said method comprising:

providing a shelter having walls and a roof but an open bottom,

placing said shelter over the right of way of the tunnel,

excavating an open trench under said shelter,

constructing a portion of tunnel structure under the rear end portion of said shelter,

moving said shelter to a series of new locations along the tunnel right of way,

excavating additional portions of the open trench un der the front portion of said shelter at the successive new locations,

and constructing additional portions of the tunnel structure under the rear portion of said shelter at the successive new locations,

whereby the tunnel building operations are substantially covered by said shelter.

2. A method according to claim 1,

in which means for the handling of materials are provided on the structure of said shelter.

3. A method according to claim 1,

in which supporting wheels are provided on said shelter for use in moving said shelter.

4. A method of building a tunnel,

said method comprising:

providing a shelter having walls and a roof but an open bottom,

moving said shelter in successive steps to a series of positions along the right of way of the tunnel,

excavating an open trench under the front portion of the shelter at each successive position,

constructing a tunnel structure under the rear portion of said shelter at each position,

said tunnel structure being constructed in the portion of the open trench which was excavated at the previous position of said shelter,

said shelter being advanced between successive positions by an amount corresponding to the length of the tunnel structure completed at the previous position of said shelter,

whereby the tunnel building operations are substantially covered by said shelter.

5. A machine for building a tunnel,

comprising a rigid framework having a pair of spaced parallel track members secured thereto,

said framework having an open space between said members,

a plurality of wheels mounted on said framework and supporting said framework for movement along a supporting surface,

a first carriage extending between said members and having rollers supported on said members for rolling movement therealong,

an excavating device mounted on said carriage for excavating earth from the space between said members,

a second carriage extending between said members and having rollers supported thereon for rolling movement therealong,

and a material handling device mounted on said second carriage for placing materials in the space between said members.

6. A method of building a tunnel, said method com prising:

providing a shelter having walls and a roof but an open bottom,

placing said shelter over the right of way of the tunnel,

excavating an open trench under said shelter,

constructing an enclosure for the trench under the rear end portion of said shelter,

moving said shelter in successive steps to a series of positions along the right of way of the tunnel,

excavating additional portions of the open trench un' der the front portion of the shelter at the successive positions,

and constructing additional portions of the enclosure for the trench under the rear portion of said shelter at the successive positions,

said shelter being moved between the successive positions by an amount corresponding to the length of the enclosure constructed at the previous position of said shelter,

whereby the tunnel building operations are substantially covered by said shelter.

7. A method of building a tunnel, said method comprising:

preparing a rigid portable enclosure,

placing said enclosure over the right of way of the tun nel,

excavating an open trench within said enclosure,

constructing a portion of tunnel structure within the rear end portion of said enclosure,

advancing said enclosure in successive steps to a series of positions along the right of way of the tunnel,

excavating additional portions of the open trench within the front portion of said enclosure at the successive positions,

and constructing additional portions of the tunnel structure within the rear end portion of said enclosure at the successive positions,

said enclosure being advanced between successive positions by an amount corresponding to the length of the tunnel structure constructed at the previous position of said enclosure whereby the tunnel building operations are carried on within said enclosure. said enclosure whereby the tunnel building operations are carried on within said enclosure.

8. A method according to claim 7,

in which means for the handling of materials are provided on the structure of said enclosure.

9. A method according to claim 7,

in which Supporting wheels are provided on said enclosure for use in moving said enclosure.

10. A method of building a tunnel, said method comprising:

providing a portable structural framework,

placing said framework upon the right of way of the tunnel,

providing movable means on said framework to support and maneuver construction equipment,

excavating an open trench under said framework,

constructing a portion of the tunnel structure under the rear end portion of said framework,

providing supporting wheels on said framework,

moving said framework on said wheels in successive steps to a series of positions along the right of way of the tunnel,

excavating additional portions of the open trench under the front portion of said framework at the successive positions,

and constructing additional portions of the tunnel structure under the rear end portion of said framework at the successive positions,

said framework being advanced between successive po sitions by an amount corresponding to the length of the tunnel structure constructed at the previous position,

whereby the tunnel building operations are carried out under said framework.

11. A machine for building a tunnel,

comprising a structure having a pair of spaced parallel members,

a plurality of wheels mounted on said structure and supporting said structure for movement along a supporting surface,

a first carriage extending between said members and having rollers supported on said members for rolling movement therealong,

an excavating device mounted on said carriage for excavating earth from the space between said members,

a second carriage extending between said members and having rollers supported thereon for rolling movement therealong,

a material handling device mounted on said second carriage for placing materials in the space between said members,

and a shelter mounted on said structure and substantially covering said structure and said first and second carriages,

said shelter having walls and a roof and a generally open bottom.

12. A machine for building a tunnel or the like,

comprising a portable enclosure having a rigid structure,

said enclosure having an open bottom to afford access to the ground within said enclosure,

an excavating device disposed within said enclosure for excavating a trench in the ground within said enclosure,

means mounting said excavating device on said structure for movement within said enclosure,

a material handling device disposed Within said enclosure for placing materials in said trench,

and means mounting said material handling device on said structure for movement within said enclosure.

13. A machine according to claim 12,

in which said enclosure has walls and a roof around said open bottom.

14. A machine according to claim 12,

comprising a plurality of wheels mounted on said enclosure and supporting said enclosure for movement along a supporting surface.

15. A machine for building a tunnel or the like,

comprising a shelter having a rigid structure including a pair of spaced parallel members,

said shelter having walls and a roof and a generally open bottom,

a plurality of wheels mounted on said shelter and supporting said shelter for movement along a supporting surface,

a first carriage extending between said members and having rollers supported on said members for rolling movement therealon g,

an excavating device mounted on said carriage for excavating earth from the space between said members,

a second carriage extending between said members and having rollers supported thereon for rolling movement therealong,

and a material handling device mounted on said second carriage for placing materials in the space between said members,

said shelter substantially covering said members and said first and second carriages.

References Cited UNITED STATES PATENTS 933,683 9/1909 Watson 5 37-84 X 892,538 7/1908 Morrill 61-41.l 1,876,496 9/1932 Goldsborough 61-44 2,789,668 4/1957 Martin 52l43 3,123,085 3/1964 Desmarteau 52-2 OTHER REFERENCES Construction Methods (pub), August 1943, pp. 62-64.

JACOB SHAPIRO, Primary Examiner,

US. Cl. X.R. 

